Peg Together Mortise and Tennon stool

Step 1: Cutting the board into sections

The board we have is a 1X12 at 6ft long. Please be aware that a 1" board is actually 3/4 inch thick.  This wood will work well for these benches, but for a longer bench you may need to add a central support or use thicker wood to prevent seat sag.

Our bench we will be making will be 18 inches tall, by 19 inches long. We will start by measuring out our board into the following measurements: 18 – 18 -17 – 19. The two 18 inch measurements will create the two legs, the 17 inch measurement will create the cross piece. The remaining board (aprox 19 inches) will create the seat.

Using your speed square set crossways on your board to guide your saw so that you get a square cut on your board. To accomplish this, place the blade of your saw on the center of your line. Place the speed square along the edge of your board and place the leg of the square against the base of the saw. As you cut, insure that your saw follows the edge of the square.

Step 2: The legs

Measure 1 inch down from the top edge of each leg panel. Now we will take the pattern for the edge sweep and the ogree arch at the base and mark them onto the leg panels. Be sure to keep the pattern lined up on the edge and the bottom edge of the 1” line.

Now we work above the 1 inch line. Measure 1 3/4” in from the edge and also measure to 3 3/4” in from the edge. Use your square to true the marks out to the edge. Now we take our jig saw and cut the excess areas away. Start with the long sweeps and then the ogree arch to build your comfort with the saw prior to cutting the tenons above the 1” line. Once these are all cut set the legs aside, and get the 17 inch piece for the cross member.

Step 3: The stretcher (cross piece)

First we will make a cut down the length that will make it 17 X 5 inches. Find the center line going crossways. Now choose one edge and make a tic mark 5 ¾ inches from either side of the center line. On the other edge, make a tick mark 5 inches to each side of the center mark. Now draw a line and connect the tic marks cross ways on the board.

The wider section is the bottom of the board. Going up the sloped line make a tic mark at the 1 inch and at the 4 inch marks on both lines. Using your carpenters square mark those 2 tick marks out to the ends. Use your jig saw to cut away the excess leaving the tennons extending from the ends of the board. As you cut the tennons use the saw to round the ends.

Now try and insert the tennons through the holes in the legs. You will find that they do not fit. Take your file and file the edges of the tennons until they fit through both slots. We do not want them to fit through one and not the other.

Once your tennons fit your mortices, place them through and mark the line showing the depth of the thickness of the legs. Put your 1 inch drill bit into your drill and put the tip of it so that the hole to be drilled will be 2/3 on the outside of the line and 1/3 on the inside.

 

The pegs are simply wedge shapes cut from the scrap that was removed from the edges of the legs. 2 pegs are required for the construction of the bench, but I suggest making 4 as you will loose pegs over time.

You should now be able to assemble your bench. Use the file to smooth out any spots that make it difficult to assemble. The tennons that come though the seat may protrude a bit. Use your pencil to mark them. Take the bench apart and then use the saw to trim them to your marked lines.

All that is left at this point is to sand the edges of all of the pieces of wood and it is now complete.  You may also choose to router the edges and then sand them. You will also need to stain and seal the bench or you may paint it.